1. Title of the invention

“Test- Bench for in-situ testing of Flap Actuator used on Military Aircraft".

2. Field of invention

The field of invention is in the testing of electronic units fitted on Fighter aircraft and the invention is a development of test-bench for in-situ testing for the actuator used in opening and closing of flaps used for cooling system on Aircraft.
3. Background of Invention

There was no methodology for in-situ testing for actuator of aircraft leading to major issues in troubleshooting of failed unit during integrated testing. Significant time was taken for removing it from aircraft and sending to Lab for testing and its • verification.

There was no prior facility available for in-situ testing, as the system for testing was devised / developed by the indigenous efforts and on the basis of the requirement of the customer.
4. Summary of the Present Invention

This invention is used to check the in-situ serviceability of Actuator used on military aircrafts for opening and closing of flaps used for cooling of units mounted on aircraft. The testing is one of the important part for in-situ serviceability check. Testing is done by manually pushing the switch up or down. When the actuator reaches, its extreme limit the respective lights will glow. Any further movement will overload the Actuator and the CB (Circuit Breaker) will break the circuit and safeguard the actuator.

5. Brief description of drawings

1. Circuit Breaker 2.5A

2. Close indicator

3. Power Indicator

4. Power Loom

5. Actual Loom

6. Spring Loaded Switch

7. Open Indicator

8. Ammeter

FIG.1 various views of Test Bench FIG.2 Layout Diagram of test bench FIG. 3 Schematic Diagram of Test Bench FIG.4 Isometric view of the Test Bench

6. Detailed description of invention

The Test bench was developed in requirement for the frequent failure of the actuator while performing the integration testing on the aircraft. The failure was mainly due to the excess current drawn while adjusting for its maximum current operation.

This in-situ testing has helped to adjust the maximum limit of actuator without damaging the actuator as the circuit-breaker is installed in source of the accumulator. Also it has drastically reduced time consumed in the removal and sending the actuator to lab.

The spring loaded switch has two way movements (up and down) for controlling the direction of movement of actuator resulting in opening and closing of ground cooling flap. The current drawn during the reverse and forward movement of actuator can be monitored by the ammeter (0-10 A) mounted on the test board arid excess current can be controlled by current breaker (CB) which disconnect the actuator of current drawn exceeds 2.5 A

BACKGROUND AND PRIOR ART
Background of Invention (origin of invention or the problem to which the invention is a solution for) The Test bench was developed in requirement for the frequent failure of the actuator while performing the integration testing on the aircraft. The failure was mainly due to the excess current drawn while adjusting for its maximum current operation. This in-situ testing has helped to adjust the maximum limit of actuator without damaging the actuator and its associated rods and brackets, as the circuit-breaker is installed in source of the accumulator. Also it has drastically reduced time consumed in the removal and sending the actuator to lab. The spring loaded switch has two way movement (up and down) for controlling the direction of movement of actuator resulting in opening and closing of ground cooling flap. The current drawn during the reverse and forward movement of actuator can be monitored by the ammeter (0-10 A) mounted on the test board and excess current can be controlled by current breaker (CR) which disconnect the actuator of current drawn exceeds 2.5 A.
Existing procedure in the same field (literature available) The Integration of the Actuator was being done on the aircraft after testing it in lab as per the test procedure mentioned by the manufacturer of the Actuator. While Integration adjustments were to be done on the aircraft and if due to any overload or any mechanical fault in the aircraft the motor linkage rod is stuck, the motor will be burnt as the motor was to be operated remotely from the cockpit and actuator is mounted in the nose cone of the Aircraft where an additional manpower needs to be supplemented for the observation, feedback and adjustments of any of actuator and the linkage rod attached to it.
Drawback of the existing procedure a. Requirement of two personnel for testing adjustment b. Failure rate was more of actuator and the connected assemblies c. Time consuming in troubleshooting for the actuator or the other associated units/spares after integration with the aircraft.
Advantages of the present invention over existing inventions No prior invention exists as the testing bench/rig was developed for specific purpose on demand of customer requirement. Following are the advantages. 1. Quick in-situ testing of Actuator 2. Easy to arrange the test setup without disassembly. 3. Reliable for in-situ testing of Actuator 4. Less time to check and adjust the actuator. 5. Only single personnel can operate and do the needful for the testing and adjustments. 6. It will help to prevent damage to linkage rod arid brackets and thus will save time and money both. 7. It will protect actuator from getting damaged due to sudden stress as it can operated in step-wise manner.
IPR APPLICATION REQUIREMENTS
Descriotion of Invention This in-situ testing has helped to adjust the maximum limit of actuator without damaging the actuator as the circuit-breaker is installed in source of the accumulator. Also it has drastically reduced time consumed in the removal and sending the actuator to lab. The spring loaded switch has two way movement (up and down) for controlling the direction of movement of actuator resulting in opening and closing of ground cooling flap. The current drawn during the reverse and forward movement of actuator can be monitored by the ammeter (0-10 A) mounted on the test board and excess current can be controlled by current breaker (CB) which disconnect the actuator of current drawn exceeds 2.5 A. It consists of following metallic & non-metallic parts: Fig.2,3,4 1. Power indicator 2. Indicator (close) 3. Indicator (Open) 4. Spring Loaded switch 5. Ammeter (0 to 10 amps ) 6. Power supply cord/Loom with respective connector of end power-supply 7. Actuator connection Loorh/Cord with respective, connector 8. Power cord(Loom) for connection between aircraft and Test bench 9. Wooden board as an enclosing cabinet 10. Hard wood board for mounting of SI. No. 1 to 5 Construction: The connection diagram is placed at Fig 3 and connections done accordingly. Accordingly the wooden board is fabricated with usual workshop practices for mountings of Electrical items.
Function : When Switch is in Neutral position Current flows through PQTBC, Close Indicator lamp offers resistance and voltage drops across it. So motor does not operate and Flap does not open and remains closed. Closed lamp Glows When Switch is in Open position Current follows PBC path and voltage passes across actuator motor and Flap opens S2 connects to Open Indicator Lamp and it glows indicating Flap is open. Switch in Close position Current follows path PAC as S2 is closed ,motor gets activated Flap gets closed S2 is opened and SI is closed now. So Close Indicator Lamp glows
Methodology for construction of invention (if applying for a product patent) The connection diagram is placed at Fig 3 and connections done accordingly which is the innovative idea behind the test bench fabrication. Accordingly the wooden board is fabricated with usual workshop practices for mountings of Electrical items.
Novelty (features that make the invention novel) CRITERIA FOR OBTAINING IP PROTECTION 1. In situ testing of actuator 2. Placing Circuit breaker in case of the excess current drawn due to fault after installation all spares and items in conjunction with Actuator. 3. Direct accessibility and visualisation by the operator to the linkage rod connected to actuator while doing adjustments.
Inventive step (are the novel features inventive enough to not be obvious to a person skilled in the art) Yes , As this is the requirement of customer for minimal overhauling cost and maximum reliability
Testing (Has the invention been tested) Invention is well Tested for its serviceability
Is the invention available as a manufactured product (If yes, provide details) Yes - ' The invention is used by the Overhaul Division Bangalore for the testing and adjustments of actuators used in Military aircrafts
Does the process/ product have industrial applicability Yes With minor or no modifications the same test can be used for other aircrafts also subjected to use of similar items on the other aircrafts.
ADDITIONAL PARAMETERS FOR OBTANING IP PROTECTION
Is the invention already in use on any platform of HAL (If so, then since when) Being used in Overhaul Division for in situ testing of actuator
Has it been published or demonstrated anywhere else/is it planned to be published or presented anywhere in the near future (details NO